Calcium-Rich Fly Ash as a Sustainable Supplementary Cementitious Material for Enhanced Sulfate Resistance and Durability of Cementitious Composites: Experimental and Microstructural Perspectives

This study explores the potential of calcium-rich fly ash from the Ptolemais region in Greece as a partial cement replacement for improving sulfate resistance in cementitious composites. An integrated experimental program, combining mechanical testing, electrochemical corrosion monitoring and microstructural characterization, was designed to capture the progression of material properties over time and their impact on performance. The experimental results proved that, at early ages, incorporation of fly ash led to reductions in compressive, tensile and bond strengths, attributed to delayed pozzolanic reactivity. However, over prolonged curing, secondary reactions consumed portlandite and generated additional calcium silicate hydrate, refining the pore network and reducing permeability. These microstructural improvements were associated with enhanced mechanical performance, improved durability indices and markedly lower reinforcement corrosion rates. Bond tests further revealed a shift from brittle to a more ductile response, offering advantages for repair applications. These findings establish calcium-rich Ptolemais fly ash as a as a sustainable and promising supplementary cementitious material that substantially enhances the long-term durability and sulfate resistance of cementitious systems.